Assembly Guide 1.1 PDF [PDF]

Zitiervorschau

BICYCLE ASSEMBLY GUIDE

Dear Customer, Congratulations on the purchase of your new bicycle! This document will help you with the final assembly and setup of your bike. We advice you to read the relevant sections before you attempt to install the components. Bicycles will be completely assembled and set up in the Bike24 workshop before delivery. The disassembly of some components solely serves the safe shipping process. The final assembly of your new bike requires just a few steps which this document will guide you through. 1 Installation of the Handlebar

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2 Installation of Front Wheel and Brake

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3 Installation of the Pedals

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4 Installation of Seat and Seatpost

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5 Electronic Shifting Systems

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6 Additional Notes

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You will likely need a set of hex keys, Torx keys and a pedal wrench. We recommend the use of a torque wrench. Do not hesitate to contact our service team should any questions or uncertainties arise. Correct assembly and setup of all components are crucial for a safe and fun riding experience with your new bicycle. Contact: ++49 (0) 351 / 417 497 - 0 [email protected] www.bike24.com

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Once you unpacked the bike it should look roughly like the following picture. Before you start with the assembly, please remove cardboard, bubble wrap and other transport protection materials carefully.

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1 Installation of the Handlebar

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The brake and shift levers are already mounted to your handlebar. The stem is mounted to the bike with the headset preload adjusted. To install the handlebar follow these steps: Loosen all bolts from the stem's bar clamp using the correct key (hex or Torx) and remove the face plate. Place the handlebar centered in the clamp. Please check carefully that no cables are twisted or kinked. On a cyclocross or road bike, align the dropbar in an angle that allows you to comfortably use the different hand positions (brake lever hoods, center section, drops). On a mountain bike, trekking or other bike that uses regular bars, align the handlebar in an angle that tilts the brake levers about 45° down.

Check of the clamp gaps: The gaps between the face plate and the body of the stem should be equal at all bolts (Fig. 02/03).

Once the handlebar is aligned, replace the stem's face plate and tighten the bolts equally in a cross diagonal pattern (Figure 01). Pay attention to the maximum tightening torques for stem and bars. The correct torques are usually noted directly on the components.

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We recommend the use of a proper torque wrench.

Your handlebar is now mounted correctly.

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2 Installation of the Front Wheel and Brake The rear wheel including quick release or thru axle is already installed. The following steps refer to the front wheel and front brake only. In some cases the front wheel is already installed as well. Should this be the case, please skip directly to the next section.

2.1 Preparing the Brake Preparing the brake requires a specific approach depending on the type of brake. 2.1.1 Hydraulic Disc Brake Remove the plastic brake pad spacer from the brake caliper. Caution: Never pull the brake lever without a brake rotor or the plastic pad spacer between the pads! You might damage the brake pistons otherwise.

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When working on the brakes you should furthermore pay attention to having clean hands, especially free from oil or grease - as a contamination of the brake pads or rotor would compromise the performance of the brake.

If there is a plastic brake pad spacer in place, remove it from the brake caliper. 2.1.3 Cable Actuated Rim Brake (V­Brake, Side Pull Brake on Road Bikes or Cantilever)

If your bike's fork is a Cannondale Lefty, loosen the brake adapter bolts so you can remove the brake caliper (Fig. 04). The bolts do not have to be removed completely.

The brake calipers are already open and ready for the installation of the wheel.

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Place the wheel in the fork's dropouts considering the correct direction. Pay attention that the hub's axle sits in the dropouts properly (Fig. 07/08). There should be no gaps towards the top of the dropouts and the fork should not rest on the quick release skewer. The quick release should not carry the load of the bike.

2.2 Mounting the Front Wheel Continue depending on the type of axle system of your bike. 2.2.1 5 mm Ø Quick Release Skewer The quick release skewer is commonly mounted with its lever to the rider's left. Check if the tire has a directional tread, which dictates the orientation of the wheel. In the case of a directional tire tread there should be a marking on the tire's sidewall, usually some sort of arrow indicating the rotation direction. On bikes featuring disc brakes the hub dictates the orientation of the wheel. The disc brake rotor will be to the rider's left.

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Remove the nut and one of the two conical springs from the rod. Insert the rod into the hollow axle of the hub and reinstall the conical spring and nut on the other side of the hub. The narrow ends of the conical springs should both face the hub (Fig. 06). Screw the nut back on. Align the quick release lever horizontally. Tighten the nut on the right side slightly and flip the lever over towards the wheel. This should require enough force to leave an imprint on the palm of your hand. You can adjust the force needed by tightening or loosening the nut while the lever is open. Once closed, most quick release levers show a labeling "CLOSE" (Fig. 09). The lever should now be aligned approximately parallel to the fork. A lever pointing downwards or forward in riding direction could get caught by obstacles and flipped open which might result in an accident.

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pointing downwards or forward in riding direction could get caught by obstacles and flipped open which might result in an accident.

2.2.2 Thru Axle

Considering the variety of systems available, we advice you to read the setup instructions of the fork's manufacturer.

If the thru axle is mounted in the fork's dropouts, please unscrew and remove it. Place the front wheel in the fork while inserting the disc brake rotor in the brake caliper. The rotor dictates the orientation of the wheel.

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Push the thru axle through the dropouts and the hollow axle of the hub (Figure 10). Depending on the design of the axle, it then needs to be clamped by bolts on the dropouts or screwed into the left dropout and fixed by closing a quick release lever (Figure 11). Pay attention to the alignment of the lever in its closed state. It should be aligned approximately parallel to the fork. A lever

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2.2.3 Cannondale Lefty

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With the disc brake rotor facing the fork, push the wheel onto the fork's axle (Figure 12). Screw in the axle bolt to pull the hub fully onto the axle. Use a torque wrench to tighten the bolt with 15 Nm (Figure 13).

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2.3 Closing the Brake

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Brakes are very critical for your safety. To ensure proper and safe operation, please follow these instructions carefully step by step. 2.3.1 Hydraulic or Cable Actuated Disc Brake Disc brakes do not need to be closed. With a Cannondale Lefty you need to reinstall the brake caliper by replacing the adapter you removed in 2.2.1 and tighten its bolts with the torque recommended by the manufacturer. 2.3.2 Cable Actuated Rim Brake (V­Brake, Side Pull Brake on Road Bikes or Cantilever) You need to close the brake caliper after installing the front wheel. The proceeding depends on the type of brake.

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2.3.2.1 V­Brake Push both brake arms together with one hand and mount the cable's metal noodle in the arm link (Figure 14). Make sure that the noodle is properly hooked up in the keyhole-shaped slot in the arm link. 2.3.2.2 Side Pull Caliper Brake (Road Bikes) 2.3.2.2.1 Campagnolo Campagnolo brakes use a mechanism on the brake lever to open and close the brake caliper for wheel removal. To close the front brake you need to pull the left brake lever slightly and then push the pin near the lever's pivot to the right in riding direction (Figure 15).

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To open the brake when needed the pin needs to be pushed in the opposite direction. 2.3.2.2.2 Shimano / SRAM Shimano and SRAM side pull caliper brakes feature an opening mechanism in form of a small lever directly on the caliper. This lever is located where the cable exits the housing and needs to be flipped down to close the brake (Figure 16). In order to open the brake when needed, you just have to flip the lever up. 2.3.2.3 Cantilever Brakes Push both brake arms together with one hand and hook up the transverse cable to the cable anchor of the free brake arm.

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2.4 Brake Operation Test Pick up the bike's front and spin the front wheel. The wheel should spin freely. Now pull the brake lever. The wheel should stop spinning immediately. If the wheel rubs against the bake pads instead of spinning freely or if the brake doesn't work properly, please recheck the steps for correct installation of the front wheel and the brake. We recommend the same operation test for the rear brake as well. Disc brake pads need to be bedded-in with the rotor to provide full performance. To do so find a safe riding area without traffic, accelerate the bike to moderate speed and then brake to walking speed to heat up the brake pads and rotors. Do not touch the rotors when they are still hot. Let the brakes cool down and repeat the procedure about 30 times.

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3 Installation of the Pedals

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Many bikes do not include pedals in delivery. Please use your existing ones or purchase a pair that suits your needs. To match the left and right pedal with the corresponding crank arm, look for an imprint on the pedals' axles. The pedal for the left crank arm in riding direction is usually marked "L" and the right one "R". We recommend that you apply some grease to the pedals' threads to prevent corrosion between the pedals and the cranks. Screw the pedals into the crank arms, the left one counterclockwise and the right one clockwise. Usually you will need a flat 15 mm open-end wrench (Figure 17) or a hex key (6 or 8 mm) to tighten the pedals. If the latter is the case, the hex key will fit the inner end of the axle, accessed through the crank arm from the inside (Figure 18). Tighten the pedals well, yet without brute force. Since there is a variety of different pedal systems available we recommend that you read the manufacturer's instructions carefully. In the case of clipless pedals you also need to install the cleats to the soles of your shoes.

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4 Installation of the Seat and Seatpost

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Bikes sold by Bike24 usually come with the saddle already installed to the seatpost. Should this not be the case, please loosen the bolts with the matching key (hex or Torx) and remove the upper part of the clamp on the top end of the seatpost. Place the saddle with its rails on the lower part of the seatpost's clamp and remount the upper part of the clamp on top of the rails. Pay attention to imprints on the rails marking a clamping range and fix the bolts slightly. To install the seatpost in your frame, please loosen the seatpost clamp. We recommend that you apply some anti-seize paste or assembly grease to the part of the seatpost that will reside in the frame. Insert the seatpost into the frame's seat tube. Pay attention to the minimum insertion recommendation marking (Figure 19). Tighten the seat clamp slightly. This is a good time to adjust the tilt of your seat. Loosen the seatpost's clamp bolts yet again to do so. We recommend aligning the saddle horizontally for a start (Figure 20). Ultimately you have to find a comfortable tilt for your liking. Tighten the clamp bolts according to the manufacturer's torque recommendations. To find the correct seat height, please align one of the crank arms pointing straight down and mount the bike with both hands on the handlebar.

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Place the heel of the matching foot on the pedal now positioned at six o'clock and adjust the seat height so your leg is fully extended. Ultimately, the seat height is a subjective matter as well and needs to suit your personal preferences. Tighten the seatpost clamp on the frame while paying attention to the maximum torque recommendation or close the quick release lever if there is one.

Your new bike is now fully assembled. Please check once again that all components are correctly installed and that both brakes are closed. Your first test ride should take place on a safe course without traffic. Make yourself familiar with the operation of the brakes! Do not hesitate to contact our Bike24 Service Team should any questions or uncertainties arise.

If your bike features a dropper post, make sure to fully extend it when determining your seat height.

Enjoy the ride! Your Bike24 Team

5 Electronic Shifting Systems If your bike is equipped with an electronic shifting system (e.g. Shimano Di2), the battery will be disconnected from the system for the shipping process. In some cases the junction box under the stem will be removed from its mount and disconnected from the STIs. To get the system ready for operation you have to place the junction box in the mount and connect all cables. Make sure not to kink or pinch the cables.

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6 Additional Notes

6.3 Inspection

6.1 Ergonomics

We recommend a basic inspection after about two months or 400 km of riding. Please check that:

Bicycle setup guides, this one included, usually contain universal recommendations of how to align and adjust certain components. These concern aspects such as height and tilt of the seat, roll of the handlebar, position and tilt of the brake levers, etc. and are supposed to provide a good starting point for you to find the best ergonomic fit. To get the most fun and best performance out of your new bike you should not be afraid to experiment with the setup options of those components in order to find the most comfortable fit to suit your personal needs and riding style.

• all bolts are still tight with the correct torque • the brakes are still correctly adjusted and the brake pads aren't worn • the air pressure in the tires is inside the range specified by the manufacturer • the tires aren't overly worn and that there are no cuts or other visible damages • the chain is lubricated well • the chainrings and rear cassette cogs are not overly worn

6.2 Suspension Setup

• the rims still run straight and round and that no spokes are loose

Most modern mountain bikes feature sophisticated suspension systems with a variety of options to customize the characteristics. To use those bikes to their full potential it is crucial to find a suspension setup that suits your individual preferences, riding style and the terrain your riding on. Since there are quite a lot of different systems available we advise you to read the setup guide provided by the manufacturer (of your fork, rear shock and/or frame). If none is included in delivery, please look it up on the manufacturer's website.

Should you find any defects that you cannot fix yourself, please contact the Bike24 Service Team or a qualified workshop. Repeat this basic inspection routine periodically to spot worn parts before they fail and keep your bicycle running safe and well.

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6.4 German Road Traffic Licensing Regulations (StVZO) Bicycles taking part in road traffic in Germany are subject to road traffic licensing regulations (Straßenverkehrszulassungsordnung / StVZO). The following requirements are compulsory (as of January 2016):

Road bikes that weigh less than 11 kg do not need the lights to be fixed to the bike. However the lights need to be carried along, ready to be attached and used at all times. Head lamps with a voltage lower than 6 V are approved in this case.

• two independently working brakes, front and rear [§ 65 StVZO] • a well audible bell [§64a StVZO] • non-slip pedals with two yellow reflectors each [§ 67 StVZO] • a fixed and ready to use light system consisting of a white head lamp and a red tail light. The lights need a product certification (K) and must be powered by one of the following sources of energy [§ 67 StVZO]: • a dynamo or generator with a power rating of at least 3 W and a voltage of 6 V • a rechargeable battery • a battery with a voltage of 6 V • two yellow spoke reflectors in each wheel, or tires with reflecting lines on both sidewalls [§67 StVZO] • one white reflector facing in riding direction [§ 67 StVZO] • one red reflector and one large red reflector marked with product certification "Z", both facing rearwards; one of the two may be integrated in the tail light [§ 67 StVZO] • faultless tires [§ 36 StVZO]

Responsible for the Content: Bike24 GmbH Breitscheidstraße 40 01237 Dresden Germany ++49 (0) 351 / 417 497 ­ 0 [email protected] www.bike24.com

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